JP2013093625A - Manufacturing method of solar cell module - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prove a manufacturing method of a solar cell module for leading out the electric output wiring from a solar cell module in laminate molding.SOLUTION: The manufacturing method of a solar cell module includes a step for placing an insulating material 10 between a solar cell 2 and a first sealing material 5 at a position corresponding to a through hole 8, and a step for bonding the solar cell 2, the insulating material 10, the first sealing material 5 and a back support member 6 by laminate molding. The step for bonding by laminate molding includes a step for covering one half of a through hole, bounded by electric output wiring 7, with a first fluororesin temporary fixing adhesive tape 14B, a step for folding the electric output wiring 7 in the sticking direction of the first fluororesin temporary fixing adhesive tape 14B, and a step for covering the entire surface of the through hole 8, the electric output wiring 7 and the first fluororesin temporary fixing adhesive tape 14B with a second fluororesin temporary fixing adhesive tape 14A.

Description

  The present invention relates to a method for manufacturing a solar cell module that generates electric power using sunlight.

  Conventional solar cell modules include those that cover the outermost surface on the light-receiving surface side with glass and those that cover with a translucent film.

  In the solar cell module that covers the light receiving surface side with glass, a moisture-resistant film is disposed on the non-light receiving surface side. This moisture resistant film has a structure in which a sealing material and an aluminum foil or a polyester film are sandwiched between weather resistant films.

On the other hand, in a solar cell module in which the light receiving surface side is covered with a translucent film, a method of adhering the translucent film and the solar cell with a sealing material is generally employed. Here, in a solar cell module for a roof that requires rigidity on the non-light-receiving surface side, a back surface support material is disposed on the non-light-receiving surface side (for example, Patent Document 1).
As the back support material, a metal plate such as a steel plate, an aluminum plate or a stainless steel plate, or carbon fiber, glass fiber reinforced plastic (FRP), ceramic, glass or the like is used.

  FIG. 12 is a plan view of a conventional solar cell module described in Patent Document 1. FIG. 13 is a cross-sectional view taken along line AA of FIG. 12 before lamination molding.

The conventional solar cell module 31 includes solar cells 32. On the surface (light-receiving surface) 32a of the solar battery cell 32, a surface sealing material 33 and a surface protection material 34 are laminated in this order. Moreover, the back surface sealing material 35 and the back surface support material 36 are laminated | stacked on the back surface (non-light-receiving surface) 32b of the photovoltaic cell 32 in the said order.
As a configuration for taking out an electrical output in such a solar cell module 31, a through hole 38 for taking out an output terminal is provided in the back surface support member 36. The electrical output wiring 37 of the solar battery cell 32 extends to the outside of the solar battery module 31 through the through hole 38. The through hole 38 is sealed with a through hole sealing material 39 after passing through the electrical output wiring 37.

  On the other hand, Patent Document 2 discloses another example of a conventional solar cell module. In Patent Document 2, a surface filler and glass (surface protective material) are laminated in this order on the surface of a solar battery cell. Moreover, the back surface filler and the back surface support material (back cover) are laminated | stacked in the said order on the back surface of the photovoltaic cell. Further, a mat member is disposed inside the back surface support material at the position of the opening of the back surface support material.

JP 2004-327698 A JP 2001-102616 A

  However, in the configuration of the above-mentioned Patent Document 1, the following problems occur when the stacked members are pressed and integrated while being heated by a laminator.

  When laminate molding is performed, as shown in FIG. 14, the solar battery cell 32 is warped due to thermal stress, and the back surface sealing material 35 flows into the through hole 38. If it does so, the edge part 32c of the photovoltaic cell 32 will approach the back surface support material 36, and the space | interval between the photovoltaic cell 32 and the back surface support material 36 will become small. Therefore, when a metal plate is used for the back surface support member 36, there is a problem in that an insulation failure occurs between the solar battery cell 32 and the back surface support material 36 after lamination molding.

  The present invention has been made in view of such circumstances, and its purpose is to produce insulation failure between the solar cell and the back surface support material even when the solar cell is warped in the laminate molding. It is an object of the present invention to provide a method for manufacturing a solar cell module with enhanced reliability and insulation.

  In order to solve the above-described problems of the prior art, the present invention is configured such that at least a first sealing material and a back surface support material are stacked in this order on one surface side of a solar battery cell. In the method for manufacturing a solar cell module, wherein a through hole is provided, and an electric output of the solar cell is output to the outside by passing an electric output wiring of the solar cell through the through hole, A step of disposing an insulating material between the solar cell and the first sealing material at a position corresponding to a through hole; the solar cell, the insulating material, the first sealing material, and the back surface; A step of covering the half of the through-hole with the first fluororesin temporary fixing adhesive tape as a boundary with the electric output wiring as a boundary. Bending the electrical output wiring in the direction in which the first fluororesin temporary fixing adhesive tape is affixed; the second fluororesin temporary fixing adhesive tape; Covering the second fluororesin temporary fixing adhesive tape.

  Moreover, according to the manufacturing method of the solar cell module of this invention, the said insulating material is comprised from the fluororesin and the 2nd sealing material, The said 1st sealing material and the said 2nd sealing. A step of disposing the fluororesin between the material and a step of adhering the second sealing material to the solar battery cell.

  In addition, after the step of bonding by the laminate molding, the step of peeling the second fluororesin temporary fixing pressure-sensitive adhesive tape and the first fluororesin temporary fixing pressure-sensitive adhesive tape, and the terminal box provided with a terminal block are supported on the back surface. Bonding to the surface of the material; electrically connecting the electrical output wiring to the terminal block; injecting an insulating sealing material into the terminal box; and attaching a lid to the terminal box; It is characterized by including.

  The insulating sealing material is a two-component curable silicone resin.

According to the solar cell module of the present invention, at least the first sealing material and the back surface support material are stacked in this order on one surface side of the solar battery cell, and the back surface support material is provided with a through hole. Corresponding to the through hole in the method of manufacturing a solar cell module configured such that the electrical output wiring of the solar battery cell is passed through the through hole to output the electrical output of the solar battery cell to the outside. A step of disposing an insulating material between the solar cell and the first sealing material at a position, and laminating the solar cell, the insulating material, the first sealing material, and the back surface support material Adhering by molding, and adhering by laminating, covering the half of the through-hole with the first fluororesin temporary fixing adhesive tape as a boundary, Bending the force wiring in the direction in which the first fluororesin temporary fixing adhesive tape is affixed, and the second fluororesin temporary fixing adhesive tape over the entire surface of the through hole, the electrical output wiring, and the first fluororesin temporary tape. A step of covering the fixing adhesive tape, and the electric output wiring is bent and fixed between the first fluororesin adhesive tape and the second fluororesin temporary fixing adhesive tape. It is possible to suppress movement during lamination. And since an electrical output wiring is hard to move, the movement of the photovoltaic cell connected to the electrical output wiring can also be suppressed.
According to the above method, even when the end portion of the solar battery cell is pushed downward at the time of laminate molding, an insulating material is interposed between the solar battery cell and the back surface support member, and insulation is ensured. In particular, in the case where a metal plate is used as the back surface support material, even if the back surface seal material around the through-hole is thinned, insulation failure between the solar battery cell and the back surface seal material can be prevented.

It is a top view of the solar cell module which concerns on embodiment of this invention. It is the sectional view on the AA line of FIG. It is sectional drawing of the insulating material which concerns on another embodiment of this invention. In the manufacturing method of the solar cell module which concerns on embodiment of this invention, it is the disassembled perspective view which showed lamination | stacking arrangement | positioning of each member. It is sectional drawing which showed the lamination | stacking arrangement | positioning of each member in the manufacturing method of the solar cell module which concerns on embodiment of this invention. It is a schematic plan view which shows the attachment structure of the electrical output wiring to a photovoltaic cell. It is a schematic plan view which shows the connection structure of the solar cell module which has arrange | positioned the several photovoltaic cell in series. In the manufacturing method of the solar cell module which concerns on embodiment of this invention, it is the disassembled perspective view which showed lamination | stacking arrangement | positioning of each member. It is sectional drawing in the manufacturing method of the solar cell module which concerns on embodiment of this invention, Comprising: It is sectional drawing of the solar cell module before lamination molding. It is sectional drawing in the manufacturing method of the solar cell module which concerns on embodiment of this invention, Comprising: It is sectional drawing of the solar cell module after lamination molding. It is the sectional view on the AA line of FIG. 1 after lamination molding. It is a top view of the conventional solar cell module. It is the sectional view on the AA line of FIG. 12 before lamination molding. It is the sectional view on the AA line of FIG. 12 after lamination molding.

  Hereinafter, a solar cell module according to an embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a plan view of a solar cell module according to an embodiment of the present invention. FIG. 2 is a cross-sectional view taken along line AA of FIG. 1 before lamination molding.

As shown in FIG. 1, the solar module 1 according to this embodiment includes solar cells 2. As shown in FIG. 2, the surface sealing material 3 and the surface protection material 4 are laminated | stacked on the surface (namely, light-receiving surface) 2a of this photovoltaic cell 2 in an order from the photovoltaic cell 2 side. Further, a back surface sealing material (first sealing material) 5 and a back surface support material 6 are laminated on the back surface (that is, the non-light-receiving surface) 2b of the solar battery cell 2 in order from the solar cell 2 side. ing. The electrical output wiring 7 extends from the solar battery cell 2 to the outside of the solar battery module 1.
From such a configuration, the solar cell module 1 is configured such that the electrical output of the solar cell 2 is output to the outside.

  As shown in FIG. 2, the back surface support member 6 is provided with a through hole 8 through which the electric output wiring 7 is passed. A through-hole sealing material 9 for sealing the through-hole 8 is disposed in the through-hole 8. The thickness of the through hole sealing material 9 is larger than the thickness of the back surface support material 6.

In the solar battery module related to the present invention, an insulating material 10 is disposed between the solar battery cell 2 and the back surface sealing material 5 at a position corresponding to the through hole 8. The insulating material 10 is provided with a first slit (cut) 10 a for allowing the electric output wiring 7 to pass therethrough. The back surface sealing material 5 is also provided with a second slit (cut) 5a for allowing the electrical output wiring 7 to pass therethrough. Further, the through-hole sealing material 9 is provided with a wiring through-hole 9 a for allowing the electrical output wiring 7 to pass therethrough.
In the present embodiment, the electrical output wiring 7 is routed through the first slit 10 a of the insulating material 10, the second slit 5 a of the back surface sealing material 5, and the wiring through hole 9 a of the through hole sealing material 9. The solar cell module 1 extends to the outside. Moreover, the electric output wiring 7 is connected to the solar battery cell 2 by a conductor such as solder.

  Next, the surface protection material 4 used in the solar cell module 1, the solar battery cell 2, the sealing material (the surface sealing material 3, the back surface sealing material 5, the through hole sealing material 9), and the back surface The support material 6 and the electrical output wiring 7 will be described in detail.

  As the surface protection material 4 of this embodiment, ethylene-tetrafluoroethylene copolymer (ETFE), polytetrafluoroethylene, tetrafluoroethylene-perfluoroalkoxy vinyl ether copolymer, tetrafluoroethylene-hexafluoropropylene copolymer A fluororesin film such as a polymer, polychlorotrifluoroethylene, chlorotrifluoroethylene-ethylene copolymer, polyvinyl fluoride, or polyvinylidene fluoride can be used. In addition, it is desirable to perform surface oxidation treatment, such as corona discharge treatment and plasma polymerization treatment, on the adhesive surface between the surface protective material 4 and the surface sealing material 3.

  As the sealing material (front surface sealing material 3, back surface sealing material 5, and through hole sealing material 9) of the present embodiment, an ethylene-vinyl acetate copolymer, silane-modified polyethylene (silane-modified PE), polyvinyl butyral. Transparent resins such as silicone resin, epoxy resin, and fluorinated polyimide can be used. These sealing materials 3, 5, and 9 can be crosslinked by adding a crosslinking agent. Moreover, it is desirable that these sealing materials 3, 5, and 9 contain an ultraviolet absorber and a light stabilizer in order to suppress light degradation.

  Here, the back surface sealing material 5 and the through hole sealing material 9 are not necessarily transparent, and may be colored. As the surface protective material 4 and the surface sealing material 3 disposed on the surface (light receiving surface) 2a of the solar battery cell 2, it is desirable to use a laminated film or sheet that has been laminated and bonded in advance.

The thickness t ₁ of the through hole for encapsulating material 9 of this embodiment, 1.5 to "the same thickness as the thickness t ₂ of the back supporting member 6,""back supporting member 6 having a thickness of t ₂ The range up to “double” is preferable (see FIG. 4). If the thickness t ₁ of the through-hole sealing material 9 is thinner than the thickness t ₂ of the back surface support material 6, the back surface sealing material 5 flows into the through holes 8 at the time of lamination molding, and the end 2 c of the solar battery cell 2 is It is pushed down. Thereby, the edge part 2c of the photovoltaic cell 2 approaches the back surface support material 6, and it becomes impossible to ensure the dielectric breakdown voltage between the photovoltaic cell 2 and the back surface support material 6.
When the thickness t ₁ of the through hole sealing material 9 is greater than 1.5 times the thickness t ₂ of the back surface support material 6, the through hole sealing material 9 reduces the back surface sealing material 5 during lamination molding. The surface sealing material 3 is pushed up through. Thereby, the surface sealing material 3 at a position corresponding to the through hole 8 becomes thin, and it becomes impossible to secure a dielectric breakdown voltage between the solar battery cell 2 and the surface protection material 4.

Furthermore, the diameter of the through-hole sealing material 9 is preferably in the range from the same length as the through-hole diameter of the through-hole 8 to the through-hole diameter of the through-hole 8 −1 mm. This is because if the diameter of the through-hole sealing material 9 is larger than the through-hole diameter of the through-hole 8, the melted through-hole sealing material 9 protrudes from the back surface support material 6 at the time of laminate molding, and the appearance is likely to be poor.
Further, when the diameter of the through hole sealing material 9 is smaller than “through hole diameter—1 mm”, the back surface sealing material 5 flows into the through hole 8 and the end portion 2 c of the solar battery cell 2 is pushed downward. Thereby, the edge part 2c of the photovoltaic cell 2 approaches the back surface support material 6, and it becomes impossible to ensure the dielectric breakdown voltage between the photovoltaic cell 2 and the back surface support material 6.

  The solar battery cell 2 of this embodiment is not particularly limited, and a semiconductor junction such as a semiconductor pn junction made of a single crystal material, a pin junction made of a non-single crystal material, or a Schottky junction is used. A silicon compound is used as the semiconductor material. Preferably, the solar battery cell 2 is made of a flexible material, and is particularly preferably an amorphous silicon (a-Si) semiconductor or a compound semiconductor formed on a stainless steel substrate or a polyimide film substrate.

  The insulating material 10 of the present embodiment is preferably a fluororesin from the viewpoints of dielectric breakdown voltage, heat resistance, and weather resistance. As the insulating material 10, polyester, polyimide, cellulose diacetate, cellulose triacetate, or the like can be used as a single film.

  As another embodiment, as shown in FIG. 3, the insulating material 10 is a laminated film or sheet in which an insulating film sealing material (second sealing material) 12 and a fluororesin 13 are stacked. Can do. In this embodiment, the insulating film sealing material 12 is disposed on the fluororesin 13. Therefore, the fluororesin 13 is disposed between the back surface sealing material 40 and the insulating film sealing material 12. In this embodiment, the insulating film sealing material 12 is laminated and bonded to the fluororesin 13 in advance.

The thickness t ₃ of the insulating material 10 may be about 5 μm to 1000 μm, and more preferably, the thickness t ₃ is about 25 μm to 600 μm. This is because if the thickness t ₃ of the insulating material 10 is 5 μm smaller, the dielectric breakdown voltage is too low and the insulating effect becomes poor. Further, if the thickness t ₃ of the insulating material 10 is larger than 1000 μm, it is difficult to deaerate the back surface sealing material 5 at the time of laminate molding.

Further, the width of the insulating material 10 (the diameter when the insulating material 10 is circular) w ₁ may be at least twice the through hole diameter w ₂ of the through hole. If the width w ₁ of the insulating material 10 is smaller than twice the through-hole diameter w ₂ , the end portion of the insulating material 10 is pushed downward when the back surface sealing material 5 is melted at the time of laminate molding. Thereby, the edge part 2c of the photovoltaic cell 2 approaches the back surface support material 6, and it becomes impossible to ensure a dielectric breakdown voltage.

Examples of the fluororesin used for the insulating material 10 include ethylene-tetrafluoroethylene copolymer, polytetrafluoroethylene, tetrafluoroethylene-perfluoroalkoxy vinyl ether copolymer, tetrafluoroethylene-hexafluoropropylene copolymer, poly A fluororesin film such as chlorotrifluoroethylene, chlorotrifluoroethylene-ethylene copolymer, polyvinyl fluoride, and polyvinylidene fluoride can be used.
Moreover, as polyester of the insulating material 10, polyester films, such as a polyethylene terephthalate, a polybutylene terephthalate, a polyethylene naphthalate, a polytrimethylene terephthalate, a polybutylene naphthalate, can be used.

In addition, the insulating film sealing material 12 is bonded to the solar battery cell 2 with an ethylene-vinyl acetate copolymer, silane-modified polyethylene (silane-modified PE), polyvinyl butyral, silicone resin, epoxy resin, fluorinated polyimide. A transparent resin such as can be used.
The insulating film sealing material 12 can be crosslinked by adding a crosslinking agent. Further, it is desirable that the insulating film sealing material 12 contains an ultraviolet absorber and a light stabilizer in order to suppress light degradation. The insulating film sealing material 12 is not necessarily transparent and may be colored. Furthermore, there is no limitation in particular as an adhesive agent for adhere | attaching the photovoltaic cell 2 and the insulating material 10, A silicone resin, an epoxy resin, a polyurethane resin etc. can be used.

  As the back surface support material 6 of this embodiment, a hot-dip galvanized steel plate, a galvalume steel plate, an aluminum plate, a metal plate such as a stainless steel plate, a plastic plate, an FRP plate, or the like can be used.

  Further, the electrical output wiring 7 of the present embodiment is a metal such as copper, aluminum, stainless steel, or nickel, and is preferably a foil and is coated with solder without exposing the metal surface.

  Next, the lamination arrangement of each member when manufacturing the solar cell module 1 will be described. FIG. 4 is an exploded perspective view showing a stacking arrangement of each member in the method for manufacturing a solar cell module according to the embodiment of the present invention. FIG. 5 is a cross-sectional view showing the stacking arrangement of each member in the method for manufacturing a solar cell module according to the embodiment of the present invention.

As shown in FIGS. 4 and 5, when manufacturing the solar cell module 1, the surface sealing material 3 and the surface protection material 4 are arranged on the light receiving side of the solar cell 2. In addition, an insulating material 10, a back surface sealing material 5, and a back surface support material 6 are disposed on the non-light-receiving side of the solar battery cell 2.
The electric output wiring 7 is connected to the solar battery cell 2 through a conductor. The electrical output wiring 7 extends to the outside of the solar cell module 1 through the first slit 10 a of the insulating material 10, the second slit 5 a of the back surface sealing material 5, and the through hole 8 of the back surface support material 6. ing.

  As shown in FIG. 5, when the solar cell module 1 is laminated, in order to prevent the melted through-hole sealing material 9 from protruding from the through-hole 8 of the back surface support material 6, a temporary fixing adhesive is used. The tape 14 is pasted so as to cover the through hole 8. In this state, lamination molding is performed.

(Example)
Next, a specific method for manufacturing the solar cell module 1 of the present invention will be described.
FIG. 6 is a schematic plan view showing a structure for attaching an electric output wiring to a solar battery cell. FIG. 7 is a schematic plan view showing a connection structure of solar cell modules in which a plurality of solar cells are arranged in series. FIG. 8 is an exploded perspective view showing a stacked arrangement of each member in the method for manufacturing a solar cell module according to the embodiment of the present invention. FIG. 9 is a cross-sectional view of the solar cell module before lamination molding.

  The solar cell module 1 of this embodiment uses a-Si solar cells 2 produced on a film substrate. Moreover, as the back support member 6, a galvalume steel plate is used.

  The film substrate a-Si solar battery cell 2 uses a polyimide film substrate having a thickness of 0.05 mm. A plurality of solar cell elements are connected in series to one surface of the substrate. Further, as shown in FIG. 6, a positive electrode extraction electrode 21 and a negative electrode extraction electrode 22 are formed on the non-light-receiving surface side which is the other surface of the substrate.

First, as the surface protective material 4, ethylene-tetrafluoroethylene (ETFE) having a thickness of 0,025 mm is used, and this ETFE is unwound from a roll film and cut into a predetermined size.
Next, 0.04 mm-thick silane-modified polyethylene is unwound from the roll film as the surface sealing material 3 and cut into a predetermined size. Then, as shown in FIG. 8, the surface sealing material 3 is disposed on the surface protection material 4. The surface protective material 4 and the surface sealing material 3 are laminated and bonded in advance to obtain an ETFE / silane-modified polyethylene (silane-modified PE) laminate film. Thereby, a manufacturing process can be simplified.

The electric output wiring 7 is made of a copper foil coated with solder, the thickness of the copper foil is 0.1 mm, and the width of the copper foil is 2 mm. When the film substrate a-Si solar battery cell 2 is manufactured, as shown in FIG. 6, a portion 7a of the electrical output wiring 7 is previously placed on the positive electrode extraction electrode 21 for terminal extraction, and a conductive adhesive tape 23 having a width of 8 mm. Use to fix.
Further, as shown in FIG. 6, the other portion 7 b of the electric output wiring 7 is bent vertically with respect to the film substrate a-Si solar battery cell 2 at a position corresponding to the through hole. Although not shown, the electric output wiring 7 is similarly fixed and bent with respect to the negative electrode extraction electrode 22.

  As shown in FIG. 8, the film substrate a-Si solar battery cell 2 as described above is disposed on the surface sealing material 3 with the light receiving surface facing downward.

Here, the case where the solar cell module which has arrange | positioned several photovoltaic cell 2A, 2B in series is demonstrated.
As shown in FIG. 7, electric output is performed on the positive electrode extraction electrode 21A of the solar cell 2A that is closest to the positive electrode and the negative electrode extraction electrode 22B of the solar cell 2B that is closest to the negative electrode using the same method as described above. Install wiring 7.
After arranging the solar cells 2A and 2B in parallel, electrical output wiring (copper foil coated with solder) so as to bridge the negative electrode extraction electrode 22A and the positive electrode extraction electrode 21B between the adjacent solar cells 2A and 2B. 7 is arranged. The entire surface of the electrical output wiring 7 is covered with a conductive adhesive tape 23, and the electrical output wiring 7 is fixed to the negative electrode extraction electrode 22A and the positive electrode extraction electrode 21B.

As shown in FIG. 8, the insulating material 10 is disposed at a position corresponding to the through hole 8 on the film substrate a-Si solar battery cell 2. As this insulating material 10, 0.025 mm-thick ETFE used as the surface protective material 4 and 0.4 mm-thick silane-modified PE film used as the surface sealing material 3 are cut into a diameter of 28 mm and used.
The insulating material 10 is formed by previously laminating and bonding the ETFE / silane-modified PE laminate film used in the surface protective material 4 and the surface sealing material 3. Thereby, a manufacturing process can be simplified. In addition, it is desirable from the viewpoint of reliability to perform lamination bonding in this way.

  As shown in FIG. 8, a first slit 10 a having a length of 20 mm is formed in a cross shape in the insulating material 10 at a position corresponding to the terminal extraction portion of the electrical output wiring 7. The first slit 10a of the insulating material 10 is produced by previously applying a blade on a flat plate. The electric output wiring 7 of the solar battery cell 2 is disposed on the non-light-receiving surface side of the solar battery cell 2 through the first slit 10a.

  As the back surface sealing material 5, a 0.4 mm thick silane-modified PE film is unwound from a roll film and used. A second slit 5 a having a length of 80 mm is formed in the back surface sealing material 5 at a position corresponding to the terminal extraction portion. The second slit 5a of the back surface sealing material 5 is prepared by previously applying a blade on a flat plate. The electric output wiring 7 of the solar battery cell 2 is disposed on the non-light-receiving surface side of the solar battery cell 2 through the first slit 10 a of the insulating material 10 and the second slit 5 a of the back surface sealing material 5.

  A 0.8 mm-thick fluororesin-coated galvalume steel sheet (Sanflon 20GL Cool, manufactured by Nippon Steel & Sumikin Steel Sheet) is used for the back support member 6. As shown in FIGS. 8 and 9, this steel plate is cut into a predetermined size in advance, and a through hole 8 having a diameter of 10 mm is provided at a position corresponding to the terminal extraction portion. In addition, on the surface of this steel plate, an acrylic resin-based electrodeposition aluminum primer (Tosprime New F, manufactured by Momentive Performance Materials Japan) is used in advance to improve the adhesion to the back surface sealing material 6. It has been applied. This primer is applied to a thickness of about 1 μm on a flat plate using a roll coater and dried at room temperature for 30 minutes or more.

A silane-modified PE film having a thickness of 0.4 mm is used as the through hole sealing material 9. This film is cut into a diameter of 9.5 mm and used. As shown in FIG. 8, the through hole sealing material 9 is provided with a wiring through hole 9 a having a diameter of 5 mm for passing the electric output wiring 7 in the center. The through-hole 9a for wiring of the sealing material 9 for through-holes is produced by punching through the sealing material 9 for through-holes in advance by applying a blade on a flat plate.
The two through-hole sealing materials 9 are disposed so as to overlap the through-holes 8 of the back surface support material 6. At this time, the electric output wiring 7 of the solar battery cell 2 is arranged so as to penetrate the wiring through hole 9 a of the through hole sealing material 9.

  Further, as shown in FIG. 9, the first fluororesin temporary fixing adhesive tape 14 </ b> B having a thickness of 0.08 mm and a width of 13 mm and the second fluororesin temporary fixing adhesive tape 14 </ b> A are attached to the back support material 6. Affix to the position of the electrical output wiring 7 coming out of the through hole 8. That is, as shown in FIG. 9, each of the first and second fluororesin temporary fixing adhesive tapes 14 </ b> B and 14 </ b> A is arranged so as to cover half of the through hole 8 with the electric output wiring 7 as a boundary. As a result, the entire exposed surface of the through hole sealing material 9 in the through hole 8 is covered with the first and second fluororesin temporary fixing adhesive tapes 14B and 14A. The electric output wiring 7 extending from the through hole 8 is bent in the direction in which the first fluororesin temporary fixing adhesive tape 14B is applied. Then, the electrical output wiring 7 is affixed onto the first fluororesin temporary fixing adhesive tape 14B by the second fluororesin temporary fixing adhesive tape 14A.

  Finally, lamination molding is performed on the members arranged in a stacked manner as shown in FIG. 9 using a vacuum thermocompression bonding method. This laminating is performed at a temperature of 140 ° C. to 150 ° C. by vacuum thermocompression bonding for 5 to 25 minutes.

FIG. 10 shows a cross-sectional view of the solar cell module 1 after lamination molding.
Before lamination molding, there is a space between the front surface sealing material 3 and the back surface sealing material 5 by the insulating material 10 as shown in FIG. When laminate molding is performed in this state, as shown in FIG. 10, the front surface sealing material 3 and the back surface sealing material 5 are melted, and the front surface sealing material 3 and the back surface sealing material 5 are in close contact with the insulating material 10. It will be. Thereby, the space between the front surface sealing material 3 and the back surface sealing material 5 is sealed.

  After the lamination molding, the second and first fluororesin temporary fixing adhesive tapes 14A and 14B are peeled off. At this time, a terminal box with a wiring cable (not shown) is bonded to the surface of the back support 6 using a one-part moisture-curing silicone resin (KE-45T, manufactured by Shin-Etsu Chemical Co., Ltd.). Here, the terminal box is made of modified polyphenylene ether (Noryl PX9406, manufactured by SABIC Innovative Plastics Japan).

The electric output wiring 7 is soldered to the terminal block of the terminal box. As the insulating sealing material at the portion where the electrical output wiring 7 is attached, a two-component curable silicone resin (KE-200 / CX-200, manufactured by Shin-Etsu Chemical Co., Ltd.) is used. This insulating sealing material is injected into the wiring portion of the electrical output wiring 7, and a lid is attached to the terminal box.
The solar cell module 1 is manufactured by the above flow.

11 is a cross-sectional view taken along line AA of FIG. 1 after lamination molding.
Before lamination molding, as shown in FIG. 1, a space is formed between the front surface sealing material 3 and the back surface sealing material 5 by the insulating material 10. When laminate molding is performed in this state, as shown in FIG. 11, the front surface sealing material 3 and the back surface sealing material 5 are melted, and the front surface sealing material 3 and the back surface sealing material 5 are in close contact with the insulating material 10. It will be. Thereby, the space between the front surface sealing material 3 and the back surface sealing material 5 is sealed. Further, according to the present embodiment, as shown in FIG. 11, even if the end 2 c of the solar battery cell 2 is pushed down after lamination molding, insulation is provided between the solar battery cell 2 and the back surface support material 6. The material 10 is interposed, and insulation is ensured.

  According to the solar cell module 1 according to the present embodiment, the back surface sealing material 5 and the back surface support material 6 are laminated in this order on the back surface 2b of the solar battery cell 2, and the back surface support material 6 has a through hole. In the solar battery module 1 configured so that the electrical output of the solar battery cell 2 is output to the outside by passing the electrical output wiring 7 of the solar battery cell 2 through the through hole 8, Since the insulating material 10 is arranged between the solar battery cell 2 and the back surface sealing material 5 at the corresponding position, even if the end 2c of the solar battery cell 2 is pushed downward at the time of laminate molding, The insulating material 10 will be interposed between the solar battery cell 2 and the back surface support material 6, and insulation will be ensured. In particular, in the case where a metal plate is used for the back surface support material 6, even if the back surface seal material 5 around the through hole 8 becomes thin, it is possible to prevent insulation failure between the solar cells 2 and the back surface seal material 6. it can.

Further, according to the solar cell module 1 according to the present embodiment, the width w ₁ of the insulating material 10 is at least twice the diameter of the through hole of the through hole 8, so that the back surface sealing material 5 is melted in the laminate molding. Even so, the insulating material 10 is surely interposed between the solar battery cell 2 and the back surface support member 6, and insulation is ensured.

Further, according to the solar cell module 1 according to this embodiment, the thickness t ₃ of the insulating material 10, because it is a thickness in the range of 5Myuemu～1000myuemu, while ensuring insulation effect, the rear surface sealing during lamination molding Deaeration between the stop material 5 and the insulating material 10 can also be performed.

  According to the solar cell module 1 according to the present embodiment, since the laminated adhesive laminated film of the surface protective material 4 and the surface sealing material 3 is used as the insulating material 10, the solar cell module 1 is not reduced without reducing reliability. Can be manufactured. Moreover, since the insulating material 10 is arrange | positioned between the photovoltaic cell 2 and the back surface sealing material 5 in the position of the through-hole 8, and the lamination molding is performed, the back surface sealing material 5 flows into the through-hole 8 and the sun. There is no possibility that the end 2c of the battery cell 2 approaches the back surface support material 6. Therefore, the electrical characteristics of the solar cell module 1 can be further improved.

  Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments, and various modifications and changes can be made based on the technical idea of the present invention.

DESCRIPTION OF SYMBOLS 1 Solar cell module 2 Solar cell 3 Surface sealing material 4 Surface protection material 5 Back surface sealing material 6 Back surface supporting material 7 Electrical output wiring 8 Through-hole 9 Through-hole sealing material 10 Insulating material 12 Insulating film sealing material 13 Fluororesin 14 Temporary Fixing Adhesive Tape 14A Second Fluororesin Temporary Fixing Adhesive Tape 14B First Fluororesin Temporary Fixing Adhesive Tape

Claims (4)

On one side of the solar battery cell, at least a first sealing material and a back surface support material are laminated in that order, the back surface support material is provided with a through hole, and the electrical output wiring of the solar battery cell is provided. In the method for manufacturing a solar cell module configured so that the electrical output of the solar cell is output to the outside by passing through the through hole,
Disposing an insulating material between the solar cell and the first sealing material at a position corresponding to the through hole;
Bonding the solar battery cell, the insulating material, the first sealing material, and the back surface support material by laminate molding,
The step of bonding by the laminate molding includes:
Covering the half of the through-hole with the first fluororesin temporary fixing adhesive tape as a boundary,
Bending the electrical output wiring in the direction in which the first fluororesin temporary fixing adhesive tape is attached;
Covering the entire surface of the through hole, the electric output wiring, and the first fluororesin temporary fixing adhesive tape with a second fluororesin temporary fixing adhesive tape;
The manufacturing method of the solar cell module characterized by including. The insulating material is composed of a fluororesin and a second sealing material,
Disposing the fluororesin between the first sealing material and the second sealing material;
The method of manufacturing a solar cell module according to claim 1, further comprising: adhering the second sealing material to the solar cell. After the step of bonding by the laminate molding,
Peeling the second fluororesin temporary fixing adhesive tape and the first fluororesin temporary fixing adhesive tape;
Bonding a terminal box with a terminal block to the surface of the back support;
Electrically connecting the electrical output wiring to the terminal block;
Injecting an insulating sealing material into the terminal box;
Attaching a lid to the terminal box;
The manufacturing method of the solar cell module of Claim 1 or 2 characterized by the above-mentioned.   The method for manufacturing a solar cell module according to claim 3, wherein the insulating sealing material is a two-component curable silicone resin.

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